Additive manufacturing with energy delivery system having rotating polygon and second reflective member

ABSTRACT

An additive manufacturing apparatus includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, and an energy delivery assembly. The energy delivery assembly includes a light source to emit one or more light beams, a first reflective member having a plurality of reflective facets, and at least one second reflective member. The first reflective member is rotatable such that sequential facets sweep the light beam sequentially along a path on the uppermost layer. The at least one second reflective member is movable such that the at least one second reflective surface is repositionable to receive at least one of the at least one light beam and redirect the at least one of at least one light beam along a two-dimensional path on the uppermost layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.15/811,547, filed on Nov. 13, 2017, which claims priority to U.S.Provisional Application Ser. No. 62/469,466, filed on Mar. 9, 2017, theentire disclosures of which are incorporated by reference.

TECHNICAL FIELD

This specification relates to an energy delivery system for additivemanufacturing, also known as 3D printing.

BACKGROUND

Additive manufacturing (AM), also known as solid freeform fabrication or3D printing, refers to a manufacturing process where three-dimensionalobjects are built up from successive dispensing of raw material (e.g.,powders, liquids, suspensions, or molten solids) into two-dimensionallayers. In contrast, traditional machining techniques involvesubtractive processes in which objects are cut out from a stock material(e.g., a block of wood, plastic or metal).

A variety of additive processes can be used in additive manufacturing.Some methods melt or soften material to produce layers, e.g., selectivelaser melting (SLM) or direct metal laser sintering (DMLS), selectivelaser sintering (SLS), fused deposition modeling (FDM), while otherscure liquid materials using different technologies, e.g.,stereolithography (SLA). These processes can differ in the way layersare formed to create the finished objects and in the materials that arecompatible for use in the processes.

Conventional systems use an energy source for sintering or melting apowdered material. Once all the selected locations on the first layerare sintered or melted and then re-solidified, a new layer of powderedmaterial is deposited on top of the completed layer, and the process isrepeated layer by layer until the desired object is produced.

SUMMARY

In one aspect, an additive manufacturing apparatus includes a platform,a dispenser to dispense a plurality of layers of feed material on a topsurface of the platform, and an energy delivery system. The energydelivery system includes a light source to emit a light beam, and areflective member that has a plurality of reflective facets. Thereflective member is positioned in a path of the light beam to receivethe light beam and redirect the light beam toward the top surface of theplatform to deliver energy to an uppermost layer of the layers of feedmaterial to fuse the feed material. The reflective member is rotatablesuch that sequential facets sweep the light beam sequentially along apath on the uppermost layer.

In another aspect, a method of additive manufacturing includesdispensing a plurality of layers of feed material on a top surface of aplatform, rotating a polygonal mirror that has a plurality of reflectivefacets, directing a light beam from a light source to the polygonalmirror and reflecting the light beam from the mirror to deliver energyto an uppermost layer of the layers of feed material to fuse the feedmaterial. Rotation of the polygonal mirror causes sequential facets ofplurality of facets to sweep the light beam sequentially along a path onthe uppermost layer.

Implementations of the aspects may include one or more of the followingfeatures.

The light source may be a laser configured to emit the light beam towardthe reflective member. The reflective facets may have substantiallyequal lengths. The reflective member may include between 4 to 30 facets.The reflective member may be a polygon mirror defining a regular convexpolygon. The path on the uppermost layer may be a line on the uppermostlayer. The line may extend across an entire width of a feed materialdelivery area on the platform.

An actuator may be operably connected to the reflective member. Theactuator may be configured to continuously rotate the reflective member,e.g., at a constant velocity between 10 and 500 rpm, to sweep the lightbeam along the path.

The reflective member may be mounted on a support. The support may bemovable in a horizontal direction that is at a non-zero angle relativeto the path such that movement of the support positions the path atsuccessive locations on the uppermost layer along the horizontaldirection. The horizontal direction may be perpendicular to the path.The dispenser may be mounted on the support so as to be moveable withand in fixed position relative to the support to dispense a plurality oflayers of feed material on a top surface of the platform. The dispensermay be configured to deliver feed material along a line substantiallyparallel to the path.

A conveyer may move the platform relative to the energy delivery systemsuch that the light beam is delivered along a profile along a horizontaldirection that is at a non-zero angle relative to the path such thatmovement of the platform positions the path at successive locations onthe uppermost layer along the horizontal direction. The horizontaldirection may be perpendicular to the path.

A controller may be configured to store data in a non-transitorycomputer readable medium, the data defining a pattern, and thecontroller may be configured to selectively operate the light source todeliver energy to the uppermost layer in the pattern defined by the datawhile the reflective member is continuously rotated.

The reflective member may be mounted on a support. The support and theplatform may be movable relative to the energy delivery system, and thepattern may include a set of parallel set of lines each at a non-zeroangle to the horizontal axis. The set of parallel lines may beperpendicular to the horizontal axis. The controller may be configuredto, in accordance to the pattern, operate the light source to deliverenergy to a first sector of the uppermost layer, and then operate thelight source to delivery energy to a second sector of the uppermostlayer, the second sector having edges distinct from edges of the firstsector. The controller may be configured to, in accordance to thepattern, operate the light source to deliver energy along a first line,and operate the light source to deliver energy along a second line at anon-zero angle to the first line. The controller may be configured tocause the light source to pulse while the reflective member is rotatedsuch that energy is delivered to a discontinuous set of voxels along afirst horizontal direction.

In another aspect, an additive manufacturing apparatus includes aplatform, a dispenser to dispense a plurality of layers of feed materialon a top surface of the platform, and an energy delivery assembly. Theenergy delivery assembly includes a light source to emit one or morelight beams, a first reflective member having a plurality of reflectivefacets, and at least one second reflective member. The first reflectivemember is positioned in a path of at least one of the light beams toreceive the at least one light beam and redirect the light beam towardthe top surface of the platform to deliver energy to an uppermost layerof the layers of feed material to fuse the feed material. The firstreflective member is rotatable such that sequential facets sweep thelight beam sequentially along a path on the uppermost layer. The atleast one second reflective member includes at least one secondreflective surface positioned in a path of at least one of the lightbeams to receive the at least one light beam. The at least one secondreflective member is movable such that the at least one secondreflective surface is repositionable to receive at least one of the atleast one light beam and redirect the at least one of at least one lightbeam along a two-dimensional path on the uppermost layer.

Implementations of the aspects may include one or more of the followingfeatures.

The one or more light sources may be one or more lasers configured toemit the light beam toward the reflective member. The light source mayinclude a first light source to generate a first light beam and a secondlight source to generate a second light beam. The first reflectivemember may be positioned in the path of the first light beam and thesecond reflective member may be positioned in the path of the secondlight beam.

The sequential facets may sweep the light beam sequentially along alinear path on the uppermost layer. The first reflective member may be apolygon mirror defining a regular convex polygon. The second reflectivemember may be a mirror galvanometer. The mirror galvanometer may includea first adjustable reflective surface to translate the light beam alonga first direction and a second reflective surface to translate the lightbeam along a second direction perpendicular to the first direction. Thesecond reflective member may include a first reflective surface movableto redirect the light beam along a first horizontal direction, and asecond reflective surface movable to redirect the light beam along asecond horizontal direction at a non-zero angle to the first horizontaldirection.

A controller may be configured to store data in a non-transitorycomputer readable medium, the data defining a region of the uppermostlayer to fuse. The controller may be configured to cause the firstreflective member to deliver energy toward an interior of the region,and cause the second reflective member to deliver energy along aperimeter of the region. The energy delivery assembly may include afirst energy delivery system including the first reflective member and afirst light source, and a second energy delivery system including thesecond reflective member and a second light source.

In another aspect, an additive manufacturing apparatus includes aplatform, a dispenser to dispense a plurality of layers of feed materialon a top surface of the platform, a first energy delivery system, and asecond energy delivery system. The first energy delivery system includesa first light source to emit a first light beam, and a first reflectivemember having a plurality of reflective facets. The first reflectivemember is positioned in a path of the first light beam to redirect thefirst light beam toward a first portion of top surface of the platformto deliver energy to a first region of an uppermost layer of the layersof feed material to fuse the feed material in the first region. Thefirst reflective member is rotatable such that sequential facets sweepthe first light beam sequentially along a linear first path on theuppermost layer. The second energy delivery system includes a secondlight source to emit a second light beam, and a second reflective memberhaving a plurality of reflective facets. The second reflective member ispositioned in a path of the second light beam to redirect the secondbeam toward a second portion of top surface of the platform to deliverenergy to a second region of the uppermost layer of the layers of feedmaterial to fuse the feed material in the second region. The secondreflective member is rotatable such that sequential facets sweep thesecond light beam sequentially along a linear second path on theuppermost layer.

Implementations of the aspects may include one or more of the followingfeatures.

The first energy system and the second energy system may be mounted on asupport that is movable relative to the platform along a firstdirection. The first direction may be at a non-zero angle relative tothe linear first path and the linear second path. The first linear pathand second linear path may be parallel. The first direction may be at aright angle to the linear first path and the linear second path. Acombination of the first path and the second path may span a workingarea of the platform.

In another aspect, an additive manufacturing apparatus includes aplatform, a dispenser to dispense a plurality of layers of feed materialon a top surface of the platform, and an energy delivery assembly. Theenergy delivery assembly includes a light source to emit a light beam, afirst reflective member having a plurality of reflective facets, and asecond reflective member comprising at least one second reflectivesurface positioned in the path of the light beam. The first reflectivemember is positioned in a path of the light beams to receive the lightbeam and redirect the light beam toward the top surface of the platformto deliver energy to an uppermost layer of the layers of feed materialto fuse the feed material. The first reflective member is rotatable suchthat sequential facets sweep the light beam sequentially along a linearpath along a first direction on the uppermost layer. The secondreflective member is movable so as to reposition the linear path along asecond direction at a non-zero angle to the first direction.

Implementations of the aspects may include one or more of the followingfeatures.

The second reflective member may be positioned in the path of the lightbeam between the light source and the first reflective member. The firstreflective member may be a polygon mirror defining a regular convexpolygon. The second reflective member may be a mirror galvanometer.

In another aspect, an additive manufacturing apparatus includes aplatform, a dispenser to dispense a plurality of layers of feed materialon a top surface of the platform, an energy delivery system, and anactuator. The energy delivery system includes a light source to emit alight beam, and a reflective member having a plurality of reflectivefacets, the reflective member positionable in a path of the light beamto receive the light beam and redirect the light beam toward the topsurface of the platform to deliver energy to an uppermost layer of thelayers of feed material to fuse the feed material. The reflective memberis rotatable such that sequential facets sweep the light beamsequentially along a linear path on the uppermost layer. The actuator isconfigured to adjust an angle of the linear path relative to theplatform.

Implementations of the aspects may include one or more of the followingfeatures.

The platform may be rotatable, and the actuator may be coupled to theplatform to rotate the platform to adjust to angle of the linear pathrelative to the platform.

The reflective member may be mounted on a rotatable support, and thereflective member is rotatable about a first axis, and the actuator iscoupled to the support to rotate the support about a second axis toadjust the angle of the linear path relative to the platform.

A controller may be coupled to the energy deliver system and theactuator and may be configured to cause the reflective member to sweepthe light beam sequentially along the linear path along a firstdirection during fusing of a first layer of the feed material, toactivate the actuator to adjust the angle of the linear path, and tocause the reflective member to sweep the light beam sequentially alongthe linear path along a second direction at a non-zero angle relative tothe first direction during fusing of a second layer of the feedmaterial. The first direction may be perpendicular to the seconddirection. The energy delivery system may be mounted on a support thatis movable relative to the platform along a third direction. The thirddirection may be at a non-zero angle relative to the first direction andthe second direction.

A controller is configured to selectively operate the light source whilethe reflective member is rotated such that the light beam is deliveredto a first region of the uppermost layer and is not delivered to asecond region of the uppermost layer, and selectively operate the lightsource while the reflective member is rotated such that the light beamis delivered to the second region of the uppermost layer and is notdelivered to the first region of the uppermost layer.

In another aspect, an additive manufacturing apparatus includes aplatform, a dispenser to dispense a plurality of layers of feed materialon a top surface of the platform, an energy delivery system, anactuator, and a controller. The energy delivery system includes a lightsource to emit a light beam, and a reflective member having a pluralityof reflective facets, the reflective member positionable in a path ofthe light beam to receive the light beam and redirect the light beamtoward the top surface of the platform to deliver energy to an uppermostlayer of the layers of feed material to fuse the feed material. Thereflective member is rotatable such that sequential facets sweep theoptical path for the light beam sequentially along a linear first pathin a first direction on the uppermost layer. The actuator is configuredto adjust a position of the linear path relative to the platform. Thecontroller is coupled to the actuator and light source and configured toselectively operate the light source while the reflective member iscontinuously rotated such a region of impingement of the light beamextends along a second path formed by activation of the light beam, thesecond path extending in a second direction at a non-zero angle to thefirst direction.

Implementations of the aspects may include one or more of the followingfeatures.

The energy delivery system may be mounted on a support that is movablerelative to the platform along a third direction at a non-zero angle tothe first direction and the actuator is coupled to the support. Thethird direction may be perpendicular to the first direction.

A second reflective member comprising at least one second reflectivesurface may be positioned in the path of the light beam. The secondreflective member may be movable by the actuator so as to reposition thelinear path along a third direction at a non-zero angle to the firstdirection. The third direction is perpendicular to the first direction.

The controller may be configured to cause the region of impingement ofthe light beam to traverse a plurality of second paths, each second pathoffset along a fourth direction perpendicular to the second direction.The plurality of second paths fill a region on the uppermost layer tofuse the region. During a first scan period, sequential adjacent ones ofthe plurality of second paths are separated in the fourth direction byat least one voxel. The controller may be configured to selectivelyoperate the light source such that each second path extends in thesecond direction during fusing of a first layer of the feed material,and to selectively operate the light source such that each second pathextends in the fifth direction at a non-zero angle relative to thesecond direction during fusing of a second layer of the feed material.

In another aspect, a method of additive manufacturing includesdispensing a plurality of layers of feed material on a top surface of aplatform, rotating a polygonal mirror that has a plurality of reflectivefacets, directing a light beam from a light source to the polygonalmirror and reflecting the light beam from the mirror to deliver energyto an uppermost layer of the layers of feed material to fuse the feedmaterial, and selectively operating the light source. Rotation of thepolygonal mirror causes sequential facets of plurality of facets tosweep an optical path of the light beam sequentially along a linearfirst path in a first direction on the uppermost layer. The light sourceis selectively operated while the polygonal mirror is continuouslyrotated such that a region of impingement of the light beam on theoutermost layer caused by activation of the light beam traverses alinear second path, the second path extending in a second direction at anon-zero angle to the first direction.

Implementations of the aspects may include one or more of the followingfeatures.

The region of impingement of the light beam may traverse a plurality ofsecond paths, each second path offset along a fourth directionperpendicular to the second direction. The plurality of second paths mayfill a region on the uppermost layer to fuse the region. The lightsource may be selectively operated such that second path extends in thesecond direction during fusing of a first layer of the feed material,and selectively operated such that second path extends in a thirddirection at a non-zero angle relative to the second direction duringfusing of a second layer of the feed material.

Advantages of the foregoing may include, but are not limited to, thefollowing. An energy delivery system in accordance to the foregoing maydeliver energy more uniformly to different portions of an uppermostlayer of feed material. In particular, the dwell time of the light beamdelivered by the energy delivery system to each voxel across the layercan be more uniform. This can prevent energy delivered by the energydelivery system from being concentrated in a particular region of thelayer of feed material due to delay required for acceleration anddeceleration of the reflective member.

In some cases, the energy delivery system can deliver the energy moreevenly across the uppermost layer of feed material than energy deliverysystems that rely on acceleration and deceleration of a reflectivemember to deliver energy to different portion of the uppermost layer offeed material. The energy delivery system can reduce energy deliveryvariation caused by changes in motion of members of the energy deliverysystem that redirect light beams toward a platform of the additivemanufacturing apparatus. For example, the energy delivery system candeliver energy consistently to outer surfaces of objects to be formed bythe additive manufacturing apparatus and interior of the objects to beformed. As a result, the surfaces of the objects can have fewer surfacedeformations than objects formed by additive manufacturing apparatusesthat deliver energy in a process that includes longer dwell times toform surfaces of the objects. Furthermore, fewer post-processingoperations are necessary to achieve a desired surface quality of theobject to be formed.

The details of one or more implementations of the subject matterdescribed in this specification are set forth in the accompanyingdrawings and the description below. Other potential features, aspects,and advantages will become apparent from the description, the drawings,and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are schematic side and top views of an example of anadditive manufacturing apparatus.

FIG. 2 is a perspective view of a reflective member.

FIGS. 3A-3C illustrate a process of scanning a light beam across aplatform.

FIG. 4 is a top view of a platform overlaid with a scanning pattern of alight beam.

FIGS. 5A and 5B are top views of platforms overlaid with examplepatterns of energy delivered to the platforms.

FIGS. 6A and 6B are schematic side and top views, respectively, ofanother example of an additive manufacturing apparatus.

FIG. 7 is a schematic side view of an energy delivery system of theadditive manufacturing apparatus of FIG. 6A.

FIGS. 8A-8C are schematic top views of further examples of additivemanufacturing apparatuses each including multiple energy deliverysystems.

FIGS. 9A-9D and 10 illustrate examples of processes to deliver energy toa platform using different patterns of energy delivery.

Like reference numbers and designations in the various drawings indicatelike elements.

DETAILED DESCRIPTION

In many additive manufacturing processes, energy is selectivelydelivered to a layer of feed material dispensed by an additivemanufacturing apparatus to fuse the feed material in a pattern, therebyforming a portion of an object. For example, a laser beam can bereflected off two galvo-driven mirrors whose positions are controlled todrive the laser beam in a vector-scan manner across the layer of feedmaterial in which the laser beam traces a vector path in a continuousmanner. Because the reflective members need to be accelerated anddecelerated to control location of the laser beam, the dwell time of thelaser beam might not be uniform across the layer.

However, a reflective member that continuously rotates in a singledirection can be used in conjunction with modulation of the light beamto control where the energy is delivered. The continuous motion of thereflective member can reduce the number of delays required for scanningthe light beam across the feed material, thus improving the throughputof objects formed by an additive manufacturing apparatus including theenergy delivery system.

Furthermore, the object to be formed can have improved surface qualitywhen energy delivered to the feed material is more consistentlydistributed. By delivering the light beam through components that moveat constant velocities, e.g., constant rotational velocity, with minimalacceleration and deceleration, the energy delivery system can improveuniformity of the dwell time of the light beam. This can reduce thelikelihood of inconsistent energy distribution.

Example Additive Manufacturing Apparatuses

Referring to FIGS. 1A and 1B, an example of an additive manufacturingapparatus 100 includes a platform 102, a dispenser 104, an energydelivery system 106, and a controller 108.

During an operation to form an object, the dispenser 104 dispensessuccessive layers of feed material 110 on a top surface 112 of theplatform 102. The energy delivery system 106 emits a light beam 114 todeliver energy to an uppermost layer 116 of the layers of feed material110, thereby causing the feed material 110 to be fused, for example, ina desired pattern to form the object. The controller 108 operates thedispenser 104 and the energy delivery system 106 to control dispensingof the feed material 110 and to control delivery of the energy to thelayers of feed material 110. The successive delivery of feed materialand fusing of feed material in each of the successively delivered layersresult in formation of the object.

The dispenser 104 can include a flat blade or paddle to push a feedmaterial from a feed material reservoir across the platform 102. In suchan implementation, the feed material reservoir can also include a feedplatform positioned adjacent the build platform 102. The feed platformcan be elevated to raise some feed material above the level of the buildplatform 102, and the blade can push the feed material from the feedplatform onto the build platform 102.

Alternatively or in addition, the dispenser can be suspended above theplatform 102 and have one or more apertures or nozzles through which thepowder flows. For example, the powder could flow under gravity, or beejected, e.g., by piezoelectric actuator. Control of dispensing ofindividual apertures or nozzles could be provided by pneumatic valves,microelectromechanical systems (MEMS) valves, solenoid valves, and/ormagnetic valves. Other systems that can be used to dispense powderinclude a roller having apertures, and an augur inside a tube having aplurality of apertures.

The feed material 110 can include metallic particles. Examples ofmetallic particles include metals, alloys and intermetallic alloys.Examples of materials for the metallic particles include aluminum,titanium, stainless steel, nickel, cobalt, chromium, vanadium, andvarious alloys or intermetallic alloys of these metals.

The feed material 110 can include ceramic particles. Examples of ceramicmaterials include metal oxide, such as ceria, alumina, silica, aluminumnitride, silicon nitride, silicon carbide, or a combination of thesematerials, such as an aluminum alloy powder.

The feed material can be dry powders or powders in liquid suspension, ora slurry suspension of a material. For example, for a dispenser thatuses a piezoelectric printhead, the feed material would typically beparticles in a liquid suspension. For example, a dispenser could deliverthe powder in a carrier fluid, e.g. a high vapor pressure carrier, e.g.,Isopropyl Alcohol (IPA), ethanol, or N-Methyl-2-pyrrolidone (NMP), toform the layers of powder material. The carrier fluid can evaporateprior to the sintering step for the layer. Alternatively, a drydispensing mechanism, e.g., an array of nozzles assisted by ultrasonicagitation and pressurized inert gas, can be employed to dispense thefirst particles.

As described herein with respect to FIGS. 2 and 3A-3C, the energydelivery system 106 includes a light source 120 to emit a light beam114. The energy delivery system 106 further includes a reflective member118 that is rotatable and that redirects the light beam 114 toward theuppermost layer 116. The reflective member 118 is rotatable to sweep thelight beam 114 along a path, e.g., a linear path, on the uppermost layer116. In conjunction with relative motion of the energy delivery system106 and the platform 102, or deflection of the light beam 114 by anotherreflector, e.g., a galvo-driven mirror, a sequence of sweeps along thepath by the light beam 114 can create a raster scan of the light beam114 across the uppermost layer 116.

As the light beam 114 sweeps along the path, the light beam 114 ismodulated, e.g., by causing the light source 120 to turn the light beam114 on and off, in order to deliver energy to selected regions of thelayers of feed material 110 and fuse the material in the selectedregions to form the object in accordance to the desired pattern.

In some implementations, the light source 120 includes a laserconfigured to emit the light beam 114 toward the reflective member 118.The reflective member 118 is positionable in a path of the light beam114 emitted by the light source 120 such that a reflective surface ofthe reflective member 118 receives the light beam 114. The reflectivemember 118 then redirects the light beam 114 toward the top surface ofthe platform 102 to deliver energy to an uppermost layer 116 of thelayers of feed material 110 to fuse the feed material 110. For example,the reflective surface of the reflective member 118 reflects the lightbeam 114 to redirect the light beam 114 toward the platform 102.

In some implementations, the energy delivery system 106 is mounted to asupport 122 that supports the energy delivery system 106 above theplatform 102. In some cases, the support 122 (and the energy deliverysystem 106 mounted on the support 122) is rotatable relative to theplatform 102. In some implementations, the support 122 is mounted toanother support 124 arranged above the platform 102. The support 124 canbe a gantry that supports the energy delivery and dispensing systems ofthe additive manufacturing apparatus 100 above the platform 102.

In some cases, the support 122 is rotatably mounted on the support 124.The reflective member 118 is rotated when the support 122 is rotated,e.g., relative to the support 124, thus reorienting the path of thelight beam 114 on the uppermost layer 116. For example, the energydelivery system 106 can be rotatable about an axis extending verticallyaway from the platform 102, e.g., an axis parallel to the Z-axis,between the Z-axis and the X-axis, and/or between the Z-axis and theY-axis. Such rotation can change the azimuthal direction of the path ofthe light beam 114 along the X-Y plane, i.e., across the uppermost layer116 of feed material.

A printhead 126 can include the support 122. The printhead 126 isarranged above the platform 102 and is repositionable along one or morehorizontal directions relative to the platform 102. The various systemsmounted to the printhead 126 can be modular systems whose horizontalposition above the platform 102 is controlled by a horizontal positionof the printhead 126 relative to the platform 102. For example, theprinthead 126 can be mounted to the support 124, and the support 124 canbe movable to reposition the printhead 126.

In some implementations, an actuator system 128 includes one or moreactuators engaged to the systems mounted to the printhead 126. In someimplementations, the printhead 126 and the constituent systems do notspan the operating width of the platform 102. In this case, the actuatorsystem 128 is operable to drive the system across the support 124 suchthat the printhead 126 and each of the systems mounted to the printhead126 are movable along the Y-axis. In some implementations (shown in FIG.1B), the printhead 126 and the constituent systems span the operatingwidth of the platform 102, and motion along the Y-axis is not necessary.

For movement along the X-axis, in some cases, the apparatus 100 furtherincludes an actuator 130 configured to drive the printhead 126 and thesupport 124 in their entireties relative to the platform 102 along theX-axis. Alternatively or additionally, the apparatus 100 includes aconveyor 132 on which the platform 102 is located. The conveyor 132 isdriven to move the platform 102 along the X-axis relative to theprinthead 126.

The actuator 130 and/or the conveyor 132 causes relative motion betweenthe platform 102 and the support 124 such that the support 124 advancesin a forward direction 133 relative to the platform 102. The dispenser104 can be positioned along the support 124 ahead of the energy deliverysystem 106 so that feed material 110 can be first dispensed, and therecently dispensed feed material can then be cured by energy deliveredby the energy delivery system 106 as the support 124 is advancedrelative to the platform 102. The dispenser can be configured to deliverfeed material along a line that spans the platform 102. As shown in FIG.1B, the dispense 104 can extend, e.g., along the Y-axis, such that thefeed material is dispensed along a line, e.g., along the Y-axis, that isperpendicular to the direction of motion of the support 124, e.g.,perpendicular to the X-axis. Thus, as the support 124 advances along,feed material can be delivered across the entire platform 102.

In some cases, the platform 102 is one of multiple platforms 102 a, 102b, 102 c. Relative motion of the support 124 and the platforms 102 a-102c enables the systems of the printhead 126 to be repositioned above anyof the platforms 102 a-102 c, thereby allowing feed material to bedispensed and fused on each of the platforms 102 a-102 c to formmultiple objects.

In some implementations, the additive manufacturing apparatus 100includes a bulk energy delivery system 134. For example, in contrast todelivery of energy by the energy delivery system 106 along a path on theuppermost layer 116 of feed material, the bulk energy delivery system134 delivers energy to a predefined area of the uppermost layer 116. Thebulk energy delivery system 134 can include a heating lamp that, whenactivated, delivers the energy to the predefined area within theuppermost layer 116 of feed material 110.

The bulk energy delivery system 134 is arranged ahead of or behind theenergy delivery system 106, e.g., relative to the forward direction 133.The bulk energy delivery system 134 can be arranged ahead of the energydelivery system 106, for example, to deliver energy immediately afterthe feed material 110 is dispensed by the dispenser 104. This initialdelivery of energy by the bulk energy delivery system 134 can stabilizethe feed material 110 prior to delivery of energy by the energy deliverysystem 106 to fuse the feed material 110 to form the object.

Alternatively, the bulk energy delivery system 134 can be arrangedbehind the energy delivery system 106, for example, to deliver energyimmediately after the energy delivery system 106 delivers energy to thefeed material 110. This subsequent delivery of energy by the bulk energydelivery system 134 can control the cool-down temperature profile of thefeed material, thus providing improved uniformity of curing. In somecases, the bulk energy delivery system 134 is a first of multiple bulkenergy delivery systems 134 a, 134 b, with the bulk energy deliverysystem 134 a being arranged behind the energy delivery system 106 andthe bulk energy delivery system 134 b being arranged ahead of the energydelivery system 106.

Optionally, the apparatus 100 includes a first sensing system 136 aand/or a second sensing system 136 b to detect properties, e.g.,temperature, density, and material, of the layer 116 as well as powderdispensed by the dispenser 104. The controller 108 can coordinate theoperations of the energy delivery system 106, the dispenser 104, and, ifpresent, any other systems of the apparatus 100. In some cases, thecontroller 108 can receive user input signal on a user interface of theapparatus or sensing signals from the sensing systems 136 a, 136 b ofthe apparatus 100, and control the energy delivery system 106 and thedispenser 104 based on these signals.

Optionally, the apparatus 100 can also include a spreader 138, e.g., aroller or blade, that cooperates with first the dispenser 104 to compactand/or spread feed material 110 dispensed by the dispenser 104. Thespreader 138 can provide the layer with a substantially uniformthickness. In some cases, the spreader 138 can press on the layer offeed material 110 to compact the feed material 110. The spreader 138 canbe supported by the support 124, e.g., on the printhead 126, or can besupported separately from the printhead 126.

In some implementations, the dispenser 104 includes multiple dispensers104 a, 104 b, and the feed material 110 includes multiple types of feedmaterial 110 a, 110 b. A first dispenser 104 a dispenses the first feedmaterial 110 a, while a second dispenser 104 b dispenses the second feedmaterial 110 b. If present, the second dispenser 104 b enables deliveryof a second feed material 110 b having properties that differ from thoseof the first feed material 110 a. For example, the first feed material110 a and the second feed material 110 b can differ in materialcomposition or average particle size.

In some implementations, the particles of the first feed material 110 acan have a larger mean diameter than the particles of the second feedmaterial 110 b, e.g., by a factor of two or more. When the second feedmaterial 110 b is dispensed on a layer of the first feed material 110 a,the second feed material 110 b infiltrates the layer of first feedmaterial 110 a to fill voids between particles of the first feedmaterial 110 a. The second feed material 110 b, having a smallerparticle size than the first feed material 110 a, can achieve a higherresolution.

In some cases, the spreader 138 includes multiple spreaders 138 a, 138b, with the first spreader 138 a being operable with the first dispenser104 a to spread and compact the first feed material 110 a and the secondspreader 138 b being operable with the second dispenser 104 b to spreadand compact the second feed material 110 b.

Referring to FIG. 2, the reflective member 118 has multiple reflectivefacets 140 each having a reflective surface that reflects receivedlight, e.g., the light beam 114. The reflective member 118 includes apolygonal mirror. The reflective facets 140 define a correspondingsegments of the polygon, with the reflective facets 140 being joined atvertices of the polygon (e.g., vertices 148 a, 148 b in FIGS. 3A-3C). Inthis regard, each of the reflective facets 140 form a continuous loopabout an axis of rotation 142 of the reflective member 118. As a result,rotation of the reflective member 118 about the axis of rotation 142enables different reflective surfaces, e.g., the reflective facets 140,to sequentially receive the light beam 114. The rotation also enablesdifferent portions of the reflective facets 140 to receive the lightbeam 114.

The reflective surfaces of the reflective facets 140, in some examples,are substantially planar surfaces. In this case, the reflective facets140 define a regular convex polygon. In some implementations, thereflective surfaces are convex or concave. In this case, the reflectivefacets 140 can define a Reuleaux polygon having sides of constantcurvature, e.g., concave or convex curvature. The reflective facets 140have substantially equal lengths. For example, each of the reflectivefacets 140 has a length between 20 and 60 mm. The number of reflectivefacets 140 is between, for example, four and thirty.

Referring to FIGS. 3A-3C, the location at which the light beam 114 isincident on a reflective facet of the reflective member 118 varies withrotation of the reflective member 118 about the axis of rotation 142.The axis of rotation 142, in some cases, is parallel to the X-axis. Thereflective member 118, when rotated about the axis of rotation 142, canspin without a change in a location along the X-axis or along the Y-axisrelative to the support 122.

The relative positions and dimensions of the reflective member 118, inconjunction with projection optics, can be such rotation of the member118 causes each facet 140 to sweep the light beam 114 across an entirewidth of the feed material delivery area 129, e.g., along the Y-axis.For example, if the reflective facet 140 defines a segment of a regularconvex polygon, as the spot where the light beam 114 impinges the facet140 moves from one vertex to the other vertex, the light beam 114 isswept along a path on the uppermost layer 116 from one end 146 a of aregion 144 of the feed material delivery area 129 to another end 146 bof the region 144 of the feed material delivery area 129, e.g., alongthe Y-axis.

In some cases, the region extends across the entire width of the feedmaterial delivery area 129. Alternatively, as described herein, theregion extends across a portion of the width of the feed materialdelivery area 129. The reflective member 118 can be repositioned toenable the energy to be delivered across the entire width of the feedmaterial delivery area 129.

In some examples, the energy delivery system 106 includes a rotaryactuator 141 operably connected to the reflective member 118. Theactuator 141 is driven to rotate the reflective member 118 about theaxis of rotation 142.

The controller 108 can be configured to cause the actuator 141 to rotatecontinuously during processing of a layer of the feed material. Thus,the reflective member 118 repeatedly sweeps the light beam 114 along thepath on the uppermost layer 116 of feed material 110. The actuator 141is configured to rotate the reflective member 118 at a constant velocitybetween 10 and 500 rpm (depending on the diameter and the number offacets of the polygon). The actuator 141 can rotate at a rate thatallows the light beam 114 to sweep across one reflective facet 140 in 1to 500 milliseconds.

Referring to FIG. 4, in some implementations, between sequentialreflective facets 140 a, 140 b, the reflective member 118 is advancedrelative to the platform 102, e.g., along the X-axis. As a result, thelight beam 114 is swept along a first path 150 a on the uppermost layer116 when the light beam 114 is swept across the first reflective facet140 a, and the light beam 114 is swept along a second path 150 b whenthe light beam 114 is swept across the second reflective facet 140 b.The paths 150 a, 150 b can be parallel. The second path 150 b of thelight beam 114 is offset along the X-axis from the first path 150 a ofthe light beam 114. Each reflective facet 140 can thus sweep along aunique path within the region 144 above the platform 102 to fusedifferent portions of the dispensed feed material 110.

As the actuator 141 is rotated, the light beam 114 scans across in afirst horizontal direction, e.g., a scanning direction 152. For example,the reflective member 118 is continuously advanced relative to theplatform 102 along the X-axis as the reflective member 118 is rotated.As a result, the path 150 a, 150 b can be parallel and can be angledrelative to Y-axis due to the motion of the reflective member 118relative to the platform 102 in the forward direction 133. Thereflective member 118 can be rotated relative to the platform 102, e.g.,through rotation of the support 122, to compensate for any angle of thepath 150 a, 150 b relative to the X-axis.

In some implementations, the actuator 130 is operated to advance thesupport 122 and thereby to advance the reflective member 118 in theforward direction 133. The support 122 is movable in a horizontaldirection, e.g., the forward direction 133, that is at a non-zero anglerelative to a path 150 swept by the light beam 114. In some cases, theforward direction 133 is perpendicular to the path 150. Alternatively,the forward direction 133 forms an angle with the path 150 that is lessthan 90 degrees. The angle can be greater than 45 degrees. Whiledescribed as being advanced through operation of the actuator 130, insome cases, the reflective member 118 is advanced relative to theplatform 102 (and hence relative to the region 144) through operation ofthe conveyor 132.

In some implementations, a path 150 of the light beam 114 swept alongthe uppermost layer 116 of feed material 110 forms a line, e.g., astraight line, on the uppermost layer 116. The path 150, for example,includes a continuous line spanning from the first end 146 a to thesecond end 146 b of the region 144. If the region 144 corresponds to thefeed material delivery area 129, the line can extend across an entirewidth of the feed material delivery area 129 on the platform 102.

Referring to FIG. 5A, the rotation of the reflective member 118 incombination with the translation of the reflective member 118 relativeto the platform 102 enables the light beam 114 to be directed across theentirety of the region 144. In some cases, the light source 120 can beselectively operated and the light beam 114 can be scanned to generatepatterns of light beam coverage spanning over a portion of the region144. The controller 108 can receive and/or store data in anon-transitory computer readable medium, with the data defining apattern of light beam coverage.

In some cases, a pattern 154 a defined by the data covers the entiretyof the region 144. The controller 108 can continuously operate the lightsource 120 such that the light beam 114 is swept along a continuous lineextending across the entire region 144, e.g., across an entire width ofthe region 144 in the scanning direction 152. The energy delivery system106 can be advanced as the light beam 114 is swept across the platform102 so that the light beam 114 can cover the entirety of the region 144by being scanned across the region 144 in accordance to the pattern 154a.

Alternatively, referring to FIG. 5B, a pattern 154 b defined by the datacovers a portion of the region 144. The pattern 154 b can cover aportion of a length of the region 144 extending in the forward direction133 and can also cover a portion of the width of the region 144extending in the scanning direction 152. Rather than controlling theactuator 141 to control the coverage of the light beam 114 along thewidth of the region 144, the controller 108 can selectively activate thelight source 120 such that the light beam 114 is only generated when thereflective member 118 is oriented to direct the light beam 114 toward afirst area 156 a of the region 144. Accordingly, the light beam 114 isnot generated when the reflective member 118 is oriented not to directthe light beam 114 toward the first area 156 a of the region 144, e.g.,oriented to direct the light beam 114 toward a second area 156 b of theregion 144. Energy is thus delivered to the area 156 a but is notdelivered to the area 156 b.

The actuator 141 is operated to continuously rotate the reflectivemember 118 during this process of selectively activating the lightsource 120 such that, when the light beam 114 is being directed towardthe region 144, the dwell time of the light beam 114 is uniform alongthe path, e.g., along the Y-axis. Similarly, the actuator 130 can beoperated to translate the energy delivery system 106 relative to theplatform 102 during this process of selectively activating the lightsource 120 such that the dwell time of the light beam 114 is uniformalong the forward direction 133, e.g., along the X-axis.

Non-uniform dwell time can cause poor surface quality of the object tobe formed, and can occur due to, for example, a reduction in speed ofthe reflective member 118 or a reversal in direction of rotation of thereflective member 118. However, because the reflective member 118 iscontinuously rotated, such dwelling of the light beam 114 can beavoided. In some cases, the light beam 114 can be selectively activated,e.g., pulsated, to selectively cure voxels of the feed material.

FIGS. 6A and 6B depict an additive manufacturing apparatus 200 similarto the additive manufacturing apparatus 100. The additive manufacturingapparatus 200 differs from the additive manufacturing apparatus 100 inthat the additive manufacturing apparatus 200 includes a second energydelivery system 204 in addition to a first energy delivery system 202.The first energy delivery system 202 is similar to the energy deliverysystem 106 described with respect to the additive manufacturingapparatus 100 and thus propagates a light beam 210 along a path on anuppermost layer 208 of feed material.

Referring also to FIG. 7, the second energy delivery system 204 includesa light source 216 to generate a light beam 206 to be swept along avector path on the uppermost layer 208 of feed material (the light beamat different positions along the path are shown by phantom lines 206 a,206 b, 206 c). The light source 216 is, for example, part of a mirrorgalvanometer. The mirror galvanometer can further include one or morereflective members 218 a, 218 b, e.g., galvo-driven mirrors. In contrastto the reflective member 118 of the energy delivery system 106 (e.g.,the reflective member of the energy delivery system 202), the reflectivemembers 218 a, 218 b of the energy delivery system 204 can beaccelerated and decelerated to achieve energy delivery along the desiredvector path. In particular, a reflective surface of the reflectivemember 218 a can be moved to control a position of the light beam 206 onthe uppermost layer 208 of feed material along the X-axis, and areflective surface of the reflective member 218 b can be moved tocontrol a position of the light beam 206 on the uppermost layer 208 offeed material along the Y-axis. The reflective members 218 a, 218 b areboth reoriented and translated along the X-axis and the Y-axis whenmoved to control the position of the light beam 206.

Referring to FIG. 6B, motion of the reflective member of the energydelivery system 202 can enable the light beam 210 to sweep across aregion 211 extending across an entire width of the platform along theY-axis. In contrast, a region 212 to which the second energy deliverysystem 204 can deliver the light beam 206 extends along both the X-axisand Y-axis. In some cases, the region 212 extends along an entire areaof a platform 214 of the additive manufacturing apparatus 200.

Rather than selective activation of the light source of the secondenergy delivery system 204 to sweep the light beam 206 along the desiredvector path, the reflective members 218 a, 218 b are moved to redirectthe light beam 206 along the desired vector path. In this regard, thelight beam 206 can be continuously emitted while the reflective members218 a, 218 b are being moved. The reflective members 218 a, 218 b canbe, for example, incrementally rotated. The reflective members 218 a,218 b can be accelerated and decelerated to adjust the trajectory of thepath of the light beam 206. Furthermore, in some cases, while the firstenergy delivery system 202 is advanced along the X-axis relative to theplatform 214 to redirect the light beam 114 along paths extending alongthe X-axis, the light beam 206 of the second energy delivery system 204can be directed along two-dimensional paths extending along both theX-axis and the Y-axis through motion of the reflective members 218 a,218 b of the second energy delivery system 204. For example, thereflective members 218 a, 218 b of the second energy delivery system 204can include multiple reflective surfaces movable such that thereflective surfaces are repositionable to receive the light beam 206 andredirect the light beam 206 along a two-dimensional path on theuppermost layer 208.

While the additive manufacturing apparatuses 100, 200 are described toinclude a single energy delivery system including a light source and arotatable reflective member, in some implementations, referring to FIGS.8A-8C, an additive manufacturing apparatus includes multiple energydelivery systems having rotatable reflective members, e.g., polygonmirrors. Referring to FIG. 8A, an additive manufacturing apparatus 300includes a first energy delivery system 302 and second energy deliverysystem 304, each energy delivery system 302, 304 including a lightsource and reflective member similar to the light source 120 and thereflective member 118 described with respect to the energy deliverysystem 106. The energy delivery systems 302, 304 are both mounted to asupport 305, e.g., similar to the support 122.

The energy delivery systems 302, 304, absent motion of the support 305along the X-axis, direct light beams along paths extending along ahorizontal direction. For example, the paths can extend along the Y-axiswithin regions 306, 308, respectively. The region 306 can overlap theregion 308. The paths can be parallel to the Y-axis, and the support 305can be incrementally advanced so that each energy delivery system 302,304 can sweep the light beams along a series of parallel paths. Theseparallel paths do not extend across the entire width of a platform 310of the additive manufacturing apparatus 300 but, when stitched together,cover a region extending across the entire width of the platform 310. Asa result, the energy delivery system 302 can deliver energy to, forexample, a first half of a platform 310, and the energy delivery system304 can deliver energy to a second half of the platform 310.

Referring to FIG. 8B, an additive manufacturing apparatus 400 differsfrom the additive manufacturing apparatus 300 in that energy deliverysystems 402, 404 of the additive manufacturing apparatus 400 arerotatable relative to a support 405 to which the energy delivery systems402, 404 are mounted. The energy delivery systems 402, 404, absentmotion of a support 405 of the additive manufacturing apparatus 400along the X-axis, direct light beams along paths extending alonghorizontal directions. For example, the paths can extend along theY-axis within regions 406, 408, respectively. In contrast to the regions306, 308, the regions 406, 408 extend along both the X-axis and Y-axisand form a non-zero angle with the Y-axis. The region 406 can overlapthe region 408. The support 405 can be incrementally advanced so thateach energy delivery system 402, 404 can sweep the light beams along aseries of parallel paths, e.g., parallel to one another but angledrelative to the Y-axis. These parallel paths do not extend across theentire width of a platform 410 of the additive manufacturing apparatus400 but, when stitched together, cover a region extending across theentire width of the platform 410. As a result, the energy deliverysystem 402 can deliver energy to, for example, a first half of aplatform 410, and the energy delivery system 404 can deliver energy to asecond half of the platform 410.

In some implementations, the energy delivery systems 402, 404 areindependently rotatable. As a result, the path of the light beam alongthe region 406 can be angled relative to the path of the light beamalong the region 408. The pattern of light beam coverage for the energydelivery system 402 can thus have paths having angles relative to theY-axis that differ from angles of paths of the pattern of light beamcoverage formed by the energy delivery system 404.

Referring to FIG. 8C, an additive manufacturing apparatus 500 differsfrom the additive manufacturing apparatus 300 in that a support 505 towhich both energy delivery systems 502, 504 are mounted is rotatablerelative to a platform 510 of the additive manufacturing apparatus 500.The paths of the light beams delivered by the energy delivery systems502, 504 can thus be rotated simultaneously with rotation of the support505. The energy delivery systems 402, 404, absent motion of a support505 of the additive manufacturing apparatus 400 along the X-axis, directlight beams along paths extending along one or both of the X-axis andthe Y-axis within regions 506, 508, respectively. As shown in FIG. 8C,in some cases, the regions 506, 508 do not extend across an entire widthof the platform 510. In addition to being movable along the X-axisrelative to the platform 510, the support 505 is movable along theY-axis relative to the platform 510 so that the energy delivery systems502, 504 to enable energy delivery to a portion 512 of the width thatthe regions 506, 508 do not cover.

In some implementations, the energy delivery systems 502, 504 areindependently rotatable relative to the support 505 in a manner similarto the energy delivery systems 402, 404.

In this regard, the angles of the light beam paths can be adjustedthrough both or either of rotation of the support 505 and independentrotation of the energy delivery systems 502, 504.

Example Patterns of Light Beam Coverage

The additive manufacturing apparatuses described herein, e.g., theadditive manufacturing apparatuses 100, 200, 300, 400, and 500, canexecute processes to generate various light beam coverage patterns.Referring to FIG. 9A, a process 600 includes an operation 602 in whichcontours defining a perimeter of an object 610 in a layer (as opposed tovoxels in the interior of the object in a layer) are formed. If thesecond energy delivery system 204 described with respect to FIGS. 6A,6B, and 7 is present, the second energy delivery system 204 can sweep alight beam across a two-dimensional vector path to cure the feedmaterial corresponding to one of the contours, e.g., one of the innerand outer contours. The data defining the pattern of light beam coveragecan define the vector path across which the light beam is swept. Thesecond energy delivery system 204 can sweep the light beam acrossanother two-dimensional vector path to cure the feed materialcorresponding to the other of the contours, e.g., the other of the innerand outer contours.

Referring to FIGS. 9A-9D, the set of operations 604A, 606A, 608A (FIG.9A) can be performed, the set of operations 604B, 606B, 608B (FIG. 9B)can be performed, the set of operations 604C, 606C, 608C (FIG. 9C), orthe set of operations 604D, 606D, 608D can be performed to fuse aninterior of the object 610, e.g., the area bounded by the contoursformed at operation 602. The operation 602 combined with the set ofoperations 604A, 606A, 608A, the set of operations 604B, 606B, 608B, orthe set of operations 604C, 606C, 608C enables the object 610 to beformed.

Referring to FIG. 9A, at operation 604A, the light beam from the energydelivery system is directed along parallel horizontal rows of anuppermost layer of feed material. The horizontal rows extend along theY-axis. The swept paths of the light beam are continuous and span acrossan entire width of the region of the feed material delivery area. Forexample, the reflective member of the energy delivery system iscontinuously rotated, and the light source is continuously activated toform one of the horizontal rows.

The horizontal rows are separated from one another by regions to whichthe light beam is not directed. In this regard, as the support to whichthe energy delivery system is mounted is advanced along the X-axis, theenergy delivery system is selectively operated to sweep the light beamalong paths separated from one another. In some cases, the support isadvanced in sufficiently large increments to enable such separationbetween the swept paths.

Alternatively, the energy delivery system is activated only duringselected incremental positions of the support, each incrementcorresponding to a single voxel of feed material. During otherincremental positions, the reflective member is continuously rotated,but the light source does not emit the light beam.

At operation 606A, the light beam from the energy delivery system isdirected along parallel horizontal rows extending along the X-axis. Thehorizontal rows are separated from one another by regions to which thelight beam is not directed. As the reflective member continuouslyrotates, the light source is selectively activated such that portions ofthe uppermost layer of feed material that receive the light beam areseparated by portions that do not receive the light beam. The lightsource is, for example, pulsed while the reflective member 118 iscontinuously rotated such that energy is delivered to a discontinuousset of voxels extending along the X-axis. In alternative examples, ifthe support for the energy delivery system is rotatable relative to theplatform, the support can be reoriented such that the energy deliverysystem can cause the light beam to sweep such horizontal rows extendingalong the X-axis.

At operation 608A, the light beam from the energy delivery system isdirected along parallel horizontal rows extending along the Y-axis. Thehorizontal rows of the operation 608A are offset from the horizontalrows of operation 604A but can be formed with similar operation of theenergy delivery system and the support.

Referring to FIG. 9B, operations 604B, 606B, and 608B differ fromoperations 604A, 606A, 608A in that the horizontal rows formed inoperations 604B and 608B are at non-zero angles relative to the Y-axisand the horizontal rows formed in operation 606B are at non-zero anglesrelative to the X-axis. In some implementations, the horizontal rowsformed in operations 604B and 608B are formed in a manner similar toformation process for the horizontal rows for operation 606C. Inparticular, the reflective member is rotatable to sweep the light beamalong a horizontal path parallel to the Y-axis, but the light source isselectively activated to form angled horizontal rows with at least onevoxel of unfused feed material. Alternatively, as described with respectto the support 122 of the additive manufacturing apparatus 100, paths ofthe light beam delivered by the energy delivery system 106 can bereoriented relative to the Y-axis such that the paths form non-zeroangles relative to the Y-axis. In this regard, the horizontal rowsformed in operations 604B and 608B can be angled through rotation of thesupport to which the energy delivery system 106 is mounted.

Similarly, the horizontal rows in operation 606B can be generatedthrough selective operation of the energy delivery system. The energydelivery system can have the same orientation as it had for operations604B and 608B. Alternatively, at operation 606B, the energy deliverysystem can be reoriented, e.g., through rotation of the support to whichthe energy delivery system is mounted.

Referring to FIG. 9C, in some implementations, sectors of the interiorof the object 610 are fused sequentially. At operation 604C, a firstsector is fused by sweeping the light beam through horizontal rows.While depicted as horizontal rows angled relative to both the X-axis andY-axis, the rows can be horizontal rows at any appropriate angle. Atoperation 606C, a second sector is fused by sweeping through horizontalrows. The horizontal rows of operation 606C can have angles similar tothe angles of the horizontal rows of operation 604C.

To allow the first sector fused at operation 604C to cool, the secondsector fused at operation 606C can be separated from the first sector,e.g., by a third sector to be fused at operation 608C. For example,edges defining the first sector can be separated from edges defining thesecond sector. This separation can provide time for the first sector tocool after fusing. Rather than continuing to deliver energy to portionsadjacent to the first sector, at operation 606C, energy is delivered tothe non-adjacent second sector. Then, at operation 608C, the thirdsector separating the first and second sectors can be fused.

Referring to FIG. 9D, in some implementations, multiple energy deliverysystems are operated to perform operations 604D, 606D, and 608D, e.g.,in accordance implementations described with respect to the additivemanufacturing apparatuses 300, 400, 500. A feed material delivery area612 to which feed material is delivered is divided into distinct regions614 a-614 d. The patterns shown in FIG. 9D for operations 604D, 606D,608D are similar to the patterns shown in FIG. 9A for operations 604A,606A, 608A. However, for operations 604D, 606D, 608D, multiple energydelivery systems are operated to deliver energy to the different regions614 a-614 d. If two energy delivery systems are present, a first of theenergy delivery systems sweeps the light beam along horizontal rows inthe region 614 a and along horizontal rows in the region 614 b foroperations 604D, 606D, 608D, and a second of the energy delivery systemssweeps the light beam along horizontal rows in the region 614 c andalong horizontal rows in the region 614 d for operations 604D, 606D, and608D.

In some implementations, the first energy delivery system sweeps thelight beam along the horizontal rows in the region 614 b while thesecond energy delivery system sweeps the light beam along the horizontalrows in the region 614 c. The first energy delivery system then sweepsthe light beam along the horizontal rows in the region 614 a while thesecond energy delivery system sweeps the light beam along the horizontalrows in the region 614 d. Because the regions 614 b, 614 c havenon-overlapping edges and the regions 614 a, 614 d have non-overlappingedges, such a sequence of fusing the feed material can reduce heatbuild-up that can occur as a result of simultaneously fusing feedmaterial in adjacent regions.

Other patterns of light beam coverage are possible. For example,referring to FIG. 10, similar to the implementations described withrespect to FIG. 9D, a feed material delivery area 712 is divided intoregions 714 a-714 d so that multiple energy delivery systems canselectively and sequentially sweep light beams through the regions 714a-714 d. In contrast to the processes described with respect to FIGS.9A-9D, in process 700, multiple sets of contours of an object 710 areformed, with one set of the contours defining a first interior portion716 a and another set of the contours defining a second interior portion716 b. As shown in operation 702, in a manner similar to that describedfor operation 702, the contours can be fused. The interior portions 716a, 716 b can then be fused at operations 704, 706, 708 to form theobject 710. As shown in operation 704, within a single region 714 a, 714b, 714 c, or 714 d, an energy delivery system can selective emit thelight beam to generate a pattern of fused material including firsthorizontal rows and second horizontal rows at a non-zero angle relativeto the first horizontal rows. The multiple energy delivery systems caneach be operated in such a manner such that each of the regions 714a-714 d can have similar patterns. Furthermore, the energy deliverysystems can deliver energy to the interior portion 716 a to form thirdhorizontal rows at a non-zero angle relative to the horizontal rows ofthe interior portion 716 b, e.g., both the first horizontal rows and thesecond horizontal rows.

Alternative Implementations

Controllers and computing devices can implement these operations andother processes and operations described herein. As described above, thecontroller 108 of the apparatus 100 can include one or more processingdevices connected to the various components, systems, and subsystems ofthe apparatus 100. The controller 108 can coordinate the operation andcause the apparatus 100 to carry out the various functional operationsor sequence of steps described above. The controller 108 can control themovement and operations of the systems of the printhead 126.

The controller 108 and other computing devices part of systems describedherein can be implemented in digital electronic circuitry, or incomputer software, firmware, or hardware. For example, the controllercan include a processor to execute a computer program as stored in acomputer program product, e.g., in a non-transitory machine readablestorage medium. Such a computer program (also known as a program,software, software application, or code) can be written in any form ofprogramming language, including compiled or interpreted languages, andit can be deployed in any form, including as a standalone program or asa module, component, subroutine, or other unit suitable for use in acomputing environment.

The controller 108 and other computing devices part of systems describedcan include non-transitory computer readable medium to store a dataobject, e.g., a computer aided design (CAD)-compatible file thatidentifies the pattern in which the feed material should be depositedfor each layer. For example, the data object could be a STL-formattedfile, a 3D Manufacturing Format (3MF) file, or an Additive ManufacturingFile Format (AMF) file. For example, the controller could receive thedata object from a remote computer. A processor in the controller 108,e.g., as controlled by firmware or software, can interpret the dataobject received from the computer to generate the set of signalsnecessary to control the components of the apparatus 100 to fuse thespecified pattern for each layer.

While this document contains many specific implementation details, theseshould not be construed as limitations on the scope of any inventions orof what may be claimed, but rather as descriptions of features specificto particular embodiments of particular inventions. Certain featuresthat are described in this document in the context of separateembodiments can also be implemented in combination in a singleembodiment. Conversely, various features that are described in thecontext of a single embodiment can also be implemented in multipleembodiments separately or in any suitable subcombination. Moreover,although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

The printhead of FIG. 1A includes several systems that enable theapparatus 100 to build objects. In some cases, instead of a printhead,an AM apparatus includes independently operated systems, includingindependently operated energy sources, dispensers, and sensors. Each ofthese systems can be independently moved and may or may not be part of amodular printhead. In some examples, the printhead includes only thedispensers, and the apparatus include separate energy delivery systemsmounted to supports independent from supports for the dispensers.

The processing conditions for additive manufacturing of metals andceramics are significantly different than those for plastics. Forexample, in general, metals and ceramics require significantly higherprocessing temperatures. Thus 3D printing techniques for plastic may notbe applicable to metal or ceramic processing and equipment may not beequivalent. However, some techniques described here could be applicableto polymer powders, e.g. nylon, ABS, polyetheretherketone (PEEK),polyetherketoneketone (PEKK) and polystyrene.

A number of implementations have been described. Nevertheless, it willbe understood that various modifications may be made. For example,

Various components described above as being part of the printhead, suchas the dispensing system(s), spreader(s), sensing system(s), heat sourceand/or energy source, can be mounted on the gantry instead of in theprinthead, or be mounted on the frame that supports the gantry.

The platform can have width between 200 mm and 2000 mm, e.g., between500 mm and 1000 mm, about 400 mm, about 500 mm, about 600 mm, about 700mm, etc.

The region to be covered by a single energy delivery system can span awidth between 100 mm to 1000 mm, e.g., between 250 mm and 500 mm, about200 mm, about 250 mm, about 300 mm, etc.

The energy delivery system 106 can be advanced incrementally along theY-axis so that the light beam can be delivered across an entire lengthof the platform 102. In some cases, the energy delivery system 106 isadvanced an increment at the end of a single path across the platform102. The light source 120 can be controlled such that the light beam 114is not emitted when the energy delivery system 106 is being advanced,for example, as the predicted location of the light beam 114 incident onthe reflective member 118 moves from one facet to another facet.

Accordingly, other implementations are within the scope of the claims.

What is claimed is:
 1. An additive manufacturing apparatus comprising: aplatform; a dispenser to dispense a plurality of layers of powder a topsurface of the platform; at least one light source to emit a first lightbeam and a second light beam, a polygon mirror scanner including a firstreflective member positioned in an optical path of the first light beamand not in an optical path of the second light beam to direct the firstlight beam toward the top surface of the platform to deliver energy toan uppermost layer of the layers of powder, the reflective member havinga plurality of reflective facets and rotatable about an axis such thatsequential facets sweep a first impingement spot of the first light beamon the uppermost layer sequentially along a predefined path on theuppermost layer, an actuator to move the predefined path relative to theplatform such that a sequence of sweeps by the first impingement spotalong the predefined path creates a raster scan by the light beam acrossthe uppermost layer, and a galvo mirror scanner including at least onereflective surface positioned in the optical path of the second lightbeam and not in the optical path of the first light beam to direct thesecond light beam toward the top surface of the platform to deliverenergy to the uppermost layer of the layers of powder, the at least onereflective surface tiltable to translate a second impingement spot ofthe second light beam on the uppermost layer in an adjustable path in afirst direction and a second direction substantially perpendicular tothe first direction.
 2. The apparatus of claim 1, wherein the predefinedpath is substantially linear.
 3. The apparatus of claim 1, comprising asupport and the polygon mirror scanner is secured to the support, andthe actuator is configured to create relative motion along a horizontalaxis between the support and the platform to move the predefined pathrelative to the platform.
 4. The apparatus of claim 3, wherein theactuator is coupled to the support and moves the support.
 5. Theapparatus of claim 3, wherein the actuator is coupled to the platformand moves the platform.
 6. The apparatus of claim 3, wherein the galvomirror scanner is secured to and moves with the support.
 7. Theapparatus of claim 1, comprising second galvo mirror scanner positionedin the optical path of the first light beam to move the predefined pathrelative to the platform and the actuator is coupled to the secondmirror galvo mirror scanner.
 8. The apparatus of claim 1, wherein thegalvo mirror scanner includes a first adjustable reflective surface inthe optical path of the second light beam to translate the secondimpingement spot along the first direction and a second reflectivesurface in the optical path of the second light beam to translate thesecond impingement spot along the second direction substantiallyperpendicular to the first direction.
 9. The apparatus of claim 1,wherein the at least one light source comprises a first light source togenerate the first light beam and a second light source to generate thesecond light beam.
 10. The apparatus of claim 1, wherein the sequentialfacets are positioned and oriented relative to the light beam to sweepthe first impingement spot of the first light beam sequentially along alinear path.
 11. The apparatus of claim 1, comprising a controllerconfigured to store data in a non-transitory computer readable medium,the data defining a region of the uppermost layer to fuse, and thecontroller is configured to cause the polygon mirror scanner to deliverenergy toward an interior of the region, and cause the galvo mirrorscanner to deliver energy along a perimeter of the region.
 12. Anadditive manufacturing apparatus comprising: a platform; a dispenser todispense a plurality of layers of feed material on a top surface of theplatform; a first energy delivery system comprising a first light sourceto emit a first light beam, and a first reflective member having aplurality of reflective facets, the first reflective member positionedin a path of the first light beam to redirect the first light beamtoward a first portion of top surface of the platform to deliver energyto a first region of an uppermost layer of the layers of feed materialto fuse the feed material in the first region, wherein the firstreflective member is rotatable such that sequential facets sweep thefirst light beam sequentially along a linear first path on the uppermostlayer; and a second energy delivery system comprising a second lightsource to emit a second light beam, and a second reflective memberhaving a plurality of reflective facets, the second reflective memberpositioned in a path of the second light beam to redirect the secondbeam toward a second portion of top surface of the platform to deliverenergy to a second region of the uppermost layer of the layers of feedmaterial to fuse the feed material in the second region, wherein thesecond reflective member is rotatable such that sequential facets sweepthe second light beam sequentially along a linear second first path onthe uppermost layer.
 13. The apparatus of claim 12, wherein the firstenergy system and the second energy system are mounted on a support thatis movable relative to the platform along a first direction.
 14. Theapparatus of claim 13, wherein the first direction is at a non-zeroangle relative to the linear first path and the linear second path. 15.The apparatus of claim 14, wherein the first linear path and secondlinear path are parallel.
 16. The apparatus of claim 15, wherein thefirst direction is at a right angle to the linear first path and thelinear second path.
 17. The apparatus of claim 12, wherein a combinationof the first path and the second path span a working area of theplatform.